ABB AV1 Operating Instructions Manual Download Page 79

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SUPPORT SERVICES

ADDITIONAL SPARE PARTS

9 - 9

Table 9-25. Type AV1 Positioner Parts List for Figure

9-3

Item

Part No.

Description

Item

Part No.

Description

5400253_3

Housing

197865_2

Stroke adjustment screw

Refer to Table

9-26

Cover assembly

197865_1

Stroke adjustment screw

5400259_1

Valve stem

NKJHA16004

Zero adjustment set screw

Refer to Table

9-26

Valve body

NBAHA16020

Span adjustment screw

5400261_1

Valve clip

Form MP481-494

Label, CSA/FM

5400263_1

Beam assembly

NIDHA13005

Indicator screw

5400264_1

Hinge

NIDHA15012

Pilot valve screw (2 req)

258544_1

Cam follower arm assembly

NBMHA13006

Diaphragm support screw

5400271_1

Spring arm

NTCHA07000

Diaphragm support scr washer

5400272_1

Pivot

NTGHA10000

Cam washer

5400273_1

eyebolt

NTJHA09030

Span adjustment washer

5400275_1

Retaining nut

Fm MP432-889

Label, indicator

Refer to Table

9-27

Cam

197893_1

Thread forming screws

Refer to Table

9-29

Cam shaft

6639559_1

Termination assembly

5400279_1

Zero adjustment nut

MP409-393

Label, terminal block

5400280_1

Range spring

1963318_ _

Nameplate, universal

Refer to Table

9-27

Manifold assembly

Refer to Table

9-29

Drive arm

193214_1

Bearing

Refer to Table

9-27

Manifold O-ring

5400286_1

Indicator

NTJHA09030

Manifold washer

Refer to Table

9-26

Small diaphragm

NBAHA16020

Manifold screw

Refer to Table

9-28

Potentiometer assembly

NBAHA16024

Manifold screw

5400292_1

Diaphragm spacer

R9025-0046

Tubing (6.4 cm (2.5 in.))

Refer to Table

9-26

Diaphragm support

1951651_1

Plug

5400294_1

Diaphragm ring

193197_1

Span adjustment bearing

Refer to Table

9-26

Diaphragm cover

114B094U01

Plug button

5400296_1

Exhaust mesh

Refer to Table

9-26

Large diaphragm

193243_1

Large position transmitter
gear

NDPAC15004

Screw

1951652_1

Barb fitting (2 req)

NTMHA13000

Lock washer

Refer to Table

9-26

Plug button

6639479_1

4 to 20-mA pos xmttr assembly

197120_28

Cam nut

Refer to Table

9-26

Bumper grommet (3 req)

19734_45

Washers

Refer to Table

9-26

Bumper grommet (2 req)

197777_50

Retaining ring, cam (2 req)

5400268_2

Bracket, pot mounting

197164_18

Retaining ring, span

193242_1

Small position xmttr gear

197227_1

Special hex head sems screw

1943187_1

Cable clip

Refer to Table

9-26

O-ring (3 req)

MP409-393

Label, connection

197843_1

Fastener, push-on, removable

MP409-393

Label, position transmitter

1945750_1

Pull plug (4 req)

5400317_1

Gear adapter

5400072_2

Knife base

NKJHA13004

Socket head cup pt set screw

5400073_1

Knife edge

NKJHA16004

Socket head cup pt set screw

NBZHA21014

Cover screw

1951041_4

Socket head pipe plug

NBZHA21040

Cover screw

Refer to Table

9-26

O-ring

NBAHA15006

Hinge screw (4 req)

NKJHA23006

Socket head cup pt set screw

NPSHA05000

Hairpin clip (2 req)

258567_1

NEMA 4X kit

NTBTF13150

Teflon washer (3 req)

5400264_2

Hinge

NBAHA13006

Diaphragm cover screw (4 req)

NOTE:

1. Refer to Tables

9-26, 9-27, 9-28 and 9-29

for quantities.

2. Items 53 & 54 replaced by SEM screw NBMHA13006A as of November 23, 2009/Serial Number 3K620000029936

Summary of Contents for AV1

Page 1: ...Characterizable Pneumatic Positioners Operating Instructions Actuators Positioners Models AV1 AV2 ...

Page 2: ...ource codes is copyrighted by ABB Inc and is owned by ABB Inc or its suppliers WARNING POSSIBLE PROCESS UPSETS Maintenance must be performed only by qualified personnel and only after securing equipment controlled by this product Adjusting or removing this product while it is in the system may upset the process being controlled Some process upsets may cause injury or damage NOTICE The information ...

Page 3: ...ATION 3 2 MOUNTING CONSIDERATIONS 3 2 MOUNTING TYPE AV POSITIONERS 3 4 TUBING CONNECTIONS 3 8 Air Supply Pressure 3 8 Air Supply Filtering 3 8 Air Supply Quality Recommended 3 9 Tubing Connections 3 9 WIRING TYPE AV2 POSITIONER 3 10 WIRING TYPE AV1 POSITIONER 3 13 RADIO FREQUENCY INTERFERENCE 3 15 WIRING REQUIREMENTS 3 15 SECTION 4 CALIBRATION 4 1 INTRODUCTION 4 1 CALIBRATION 4 1 Zero Adjustment 4...

Page 4: ...I P Converter 8 4 Cam 8 5 Diaphragm Assembly 8 5 DIAPHRAGM ASSEMBLY REMOVAL 8 6 DIAPHRAGM ASSEMBLY REPLACEMENT 8 6 PILOT VALVE STROKE ADJUSTMENT 8 7 SECTION 9 SUPPORT SERVICES 9 1 INTRODUCTION 9 1 RECOMMENDED SPARE PARTS 9 1 ADDITIONAL SPARE PARTS 9 3 APPENDIX A POSITION TRANSMITTERS A 1 INTRODUCTION A 1 DESCRIPTION AND OPERATION A 1 CALIBRATION A 2 Calibrating the Potentiometric Position Transmit...

Page 5: ...ft Variations 3 5 3 5 Mounting Using Linkage Typical 3 5 3 6 Mounting Using Direct Coupling Typical 3 6 3 7 Cam 3 7 3 8 Cam Roller Alignment 3 8 3 9 Port Locations 3 9 3 10 Direct Acting Top Loaded Single Acting Tubing Example 3 11 3 11 Reverse Acting Top Loaded Single Acting Tubing Example 3 12 3 12 Direct Acting Bottom Loaded Single Acting Tubing Example 3 12 3 13 Reverse Acting Bottom Loaded Si...

Page 6: ...ded Single Acting Tubing Example B 6 B 8 Direct Acting Bottom Loaded Single Acting Tubing Example B 7 B 9 Reverse Acting Bottom Loaded Single Acting Tubing Example B 7 B 10 Double Acting Tubing Example B 8 B 11 Wiring Connections B 9 B 12 Calibration Adjustments B 9 C 1 Cam A Square Root Relationship C 1 C 2 Cam B Linear Relationship C 2 C 3 Cam C Square Relationship C 2 C 4 Regulated Device Chara...

Page 7: ...itioner Mounting Kit Number 5327321 121 9 5 9 21 Positioner Mounting Kit Number 5327321 131 9 5 9 22 Positioner Mounting Kit Number 5327321 141 for use on Fisher Actuators 9 6 9 23 Rotary Actuator Retrofit Mounting Kits 9 7 9 24 Bypass Valve Assembly Optional 9 7 9 25 Type AV1 Positioner Parts List 9 9 9 26 Input Signal Parts Reference for Type AV1 Positioners 9 10 9 27 Cam Selection and Manifold ...

Page 8: ... must be free of any hazardous materials acids alkalis solvents etc A Material Safety Data Sheet MSDS for all process liquids must accompany returned equipment Contact the factory for authorization prior to returning equipment Read these instructions before starting installation save these instructions for future reference Contacting the Factory Should assistance be required with any of the compan...

Page 9: ...ed in Section 3 and Section 4 respec tively INTENDED USER The information in this instruction is a guide for technical person nel responsible for installation calibration operation maintenance and repair of the positioner DESCRIPTION The Type AV1 and Type AV2 positioners are control devices that satisfy a wide range of applications They provide fast sensitive and accurate positioning of pneumatic ...

Page 10: ...r instru ment indication internal input signal and two for output indication The gage block does not provide filters or means of isolating the positioner from the actuator Installation of a supply gage is possi ble in the supply line piping by customer Both positioners can be equipped with either an optional potentio metric or a four to 20 milliamp position transmitter that provides additional con...

Page 11: ...osionproof conduit entrance on the I P converter If no electrical connections are made within the main housing the entire positioner can be considered suitable for application in the hazardous locations shown on the I P label Refer to Figure 3 1 for the external and mounting dimensions of the Type AV27 positioner NEMA 4X Option The Type AV N positioner comes with a NEMA 4X housing To maintain the ...

Page 12: ... permits operation using natural gas Split Range Service Split range capability allows sequencing of multiple actuators using a single control signal Adjustable Gain Two levels of gain are possible by changing the hinge springs supplied with the positioner Adaptable Usage The positioner can control both single and double acting linear and rotary type actuators High Capacity More than 0 65 cubic me...

Page 13: ... adjustment procedures Operating Procedures Presents information and procedures for various applications Troubleshooting Provides a table containing errors causes and corrective action Maintenance Includes preventive maintenance information and procedures Repair and Replacement Procedures in this section give step by step instructions for removing and replacing components Support Services Provides...

Page 14: ...ositioners with Analog Input Signals and Pneumatic Output Instrument Society of America P P88 001 Product Application Guide Installing a Type AV Positioner in a Hazardous Location Table 1 2 Nomenclature Position 1 2 3 4 5 6 7 8 9 Type A V _ _ _ _ _ _ _ Characterizable Positioners 1 Characterizable Pneumatic Positioner 2 Characterizable 4 to 20 mA Input Positioner actuator moves to 0 or 100 upon lo...

Page 15: ...flats UP1 and UP2 after August 1995 4 0 375 in square for DeZurik PowerRac actuators 5 0 156 in across flats for NAMUR rotary actuators Other Options 0 Standard no other options N NEMA 4X enclosure rating when installed per drawing C258567 P Performance Series high pneumatic gain for large actuators NOTES 1 High temperature Type AV1 positioners are only available without manifolds or position tran...

Page 16: ...34 kPa 25 to 150 psig NOTE Minimum supply pressure should be 34 4 kPa 5 0 psig above operating pres sure required by actuator Supply pressure effect 0 05 per 6 9 kPa for 69 kPa change 0 05 per 1 0 psi for 10 psig change Capacity maximum capacity exhaust ing to atmosphere Refer to Figure 1 1 Air consumption Refer to Figure 1 2 Vibration effect2 2 0 error for 5 to 15 Hz at peak to peak constant disp...

Page 17: ...erating 0 to 95 noncondensing Storage 0 to 95 noncondensing NOTES 1 Performance testing performed on a ABB Type UP10 actuator 2 Tested according to ISA S75 13 1989 3 For operation below 4 4 C 40 F dew point of the supply air must be 10 C 18 F lower than the lowest expected operating temperature SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Table 1 3 Type AV1 2 Positioner Specifications1 continue...

Page 18: ...60 0 70 0 00 20 150 30 40 50 60 70 80 90 100 110 120 130 140 AV2 AV1 Figure 1 3 Output Air Flow vs Error Signal Standard and Performance Series OUTPUT AIR FLOW SCFM ERROR 25 20 25 15 15 20 5 5 10 10 20 10 15 5 5 15 20 10 O1 SUPPLYING O2 EXHAUSTING O2 SUPPLYING O1 EXHAUSTING STANDARD STANDARD PERFORMANCE SERIES PERFORMANCE SERIES T00813A ...

Page 19: ...mum Maximum voltage 35 VDC or 30 VAC across the potentiometer ends Temperature limits Operating 40 C to 82 C 40 F to 180 F Storage 40 C to 93 C 40 F to 200 F SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Table 1 5 Type AV____2 __ 4 to 20 mA Position Transmitter Specifications Property Characteristic Value Supply voltage 16 to 34 VDC Output signal 4 to 20 mA Output loading 500 Ω at 24 VDC 1000 Ω ...

Page 20: ...r installing the positioner in a hazardous location refer to Product Application Guide Installing a Type AV Positioner in a Hazard ous Location Table 1 7 Accessories1 Accessory Description Mounting kits Dependent on valve stem size Figure 9 1 kit number 5327321__ For ABB retrofit kits refer to Table 1 8 Speed control orifices Regulate time constant of positioner and final control device Orifices a...

Page 21: ...10 Pressure Gages Part Number Legend Range kPa psig 5326605_4 Instrument 0 to 200 0 to 30 5326605_5 Supply1 0 to 1 000 0 to 160 5326605_6 Output 0 to 1 000 0 to 160 NOTE 1 The optional manifold provides gage ports one for instrument internal input signal and two out put gages A supply gage can be installed in the supply line piping by customer Table 1 11 Supply Air Regulators with Gages Part Numbe...

Page 22: ...Spring arm Aluminum Zero adjustment nut Aluminum Indicator Valox unreinforced polybutylene terphthalate Tubing Silicone Drive arm Aluminum Teflon washers Teflon Fasteners Steel stainless steel Signal connector Nylon Diaphragms All except Types AV15 and AV16 Buna N with Dacron fabric Types AV15 and AV16 Fluorosilicone with Dacron fabric Diaphragm plastic parts Rynite FR 530 polyethylene ter phthala...

Page 23: ...ne 1 Regulator bracket 1 304 stainless steel 1 Tubing Nylon I P converter Copper Copper clad glass laminate Monel 405 Nickel iron Noryl phenylene ether phenylene Polyethylene Polyester magnet wire Rare earth magnet Zinc Table 1 13 Component Material List Component Material NOTE 1 Regulator not applicable for AV2 s after July 2001 ...

Page 24: ......

Page 25: ...gure 2 2 shows the placement of a positioner in a typical control system Figure 2 1 Operation Diagram PILOT VALVE CAM SIGNAL DIAPHRAGM DIAPHRAGM FORCE RANGE SPRING FORCE RANGE SPRING T00354A GAIN HINGE SPRING BALANCE BEAM INPUT SIGNAL PRESSURE SUPPLY PRESSURE TO ACTUATOR TO ACTUATOR O1 O2 S Figure 2 2 Block Diagram SET POINT CONTROLLER POSITION TRANSMITTER OPTIONAL POSITIONER ACTUATOR PROCESS OUTP...

Page 26: ...on is a function of the actuator position A change in input signal changes the force exerted by the signal diaphragm moving the balance beam in turn moving the pilot valve The pilot valve supplies and or exhausts air to the actuator that ultimately changes its position The change in actuator posi tion is fed back to the positioning cam The positioning cam moves changing the tension of the range sp...

Page 27: ...the major points of installation and calibration Detailed installation and calibration information is contained in this section and in Section 4 UNPACKING AND INSPECTION 1 Check for obvious damage to the shipping carton 2 Open the carton and remove all loose packing 3 Carefully remove the positioner from the carton and inspect for any physical damage that may have occurred during shipping 4 Remove...

Page 28: ...nded corrosion resistance requirements of NEMA 250 A NEMA 4X version is available as an option Type AV______N positioners To maintain the NEMA 4X classification the posi tioner shall be installed per drawing C258567 and suitable piping shall be attached to the vent opening and vented in a manner to preclude the entrance of water under pressure as from a hose Additionally the conduit connections sh...

Page 29: ...0 250 FASTENERS FAR SIDE APPROX 45 MOTION FOR 1 2 TRAVEL CAM 2X 0 312 18UNC 2B THRU MOUNTING HOLES SEE ELECTRICAL CONNECTIONS FIGURE VENT HOLE 1 2 14 NPT SEE NOTE 3 SEE NOTE 3 SEE NOTE 1 6 76 171 7 5 32 135 1 3 10 78 8 2 25 57 2 6 49 164 9 2 10 53 3 1 80 45 7 3 00 76 2 SEE NOTE 3 OUTPUT CONN O1 1 4 18 NPT SEE NOTE 5 O1 O2 O2 O1 O1 O2 I I I S S OUTPUT CONN O2 1 4 18 NPT SEE NOTE 5 AIR FILTER 3 1 8 ...

Page 30: ...unting and external dimensions are shown in Figure 3 1 Figure 3 5 shows a typical mounting arrangement using a ABB mounting kit Refer to Figure 9 23 for an exploded view and complete parts list of Figure 3 2 Electrical Connections Figure 3 3 Drive Arm Connections ELECTRICAL CONNECTIONS CUSTOMER SUPPLIED SIGNAL AV23 W ITH 5400253_1 HOUSING AV23 AV 2 4 20 M A OUTPUT POSITIO N TRANSMITTER OPTION AV 1...

Page 31: ...ANE T00927A TYPE AV 3 0 250 IN FLATS 6 35 0 250 7 21 0 284 5 84 0 230 TYPE AV 4 0 375 IN SQUARE END FOR DEZURIK POW ER RAC ACTUATO RS 8 13 0 320 17 3 0 680 9 53 0 375 TYPE AV 2 0 342 IN SQUARE END 17 3 0 680 17 1 0 675 8 69 0 342 TYPE AV 1 0 5 IN SQUARE END 20 8 0 820 12 7 0 500 DIMENSIONS MILLIMETERS INCHES 4 06 160 4 06 160 24 64 970 TYPE AV 5 0 156 IN FLATS 6 35 0 250 TYPE AV POSITIONER ELASTIC...

Page 32: ... that will provide the required direction of rotation A direct acting black positioning cam with segments A B and C Fig 3 7 and a reverse acting cam are furnished with each posi tioner The reverse acting cam has red radial lines and arcs and is stored on the inside of the positioner cover Cam A is for a square root function cam B is for linear motion and cam C is for a Figure 3 6 Mounting Using Di...

Page 33: ... by nomenclature Figure 3 7 Each cam shape A B or C has its own eight point center hole for mounting on the camshaft Fig 3 7 Place the cam in one of the eight 45 degree positions so that the midpoint of the cam corre sponds to the mid stroke of the actuator The drive arm should be perpendicular to the motion of the actuator with the actuator at mid stroke 3 Adjust the connecting linkage so that th...

Page 34: ... per square inch gage above the operating pres sure required by the actuator Air Supply Filtering An external filter is recommended for Type AV positioners for pri mary filtration of the supply air ABB provides supply air filters as accessories Refer to Table 1 12 for part numbers NOTE Primary air supply filters are recommended for position ers with a manifold AV___1 2___ without a manifold AV___0...

Page 35: ...inimum temperature to which any part of the instrument air system is exposed The pressure dew point shall not exceed 4oC 39oF at line pres sure The oil content should be as close to zero as possible and under no circumstances shall it exceed one 1 ppm w w or v v Instrument air should be free of corrosive contaminants and hazardous gases which could be drawn into the instrument air supply In additi...

Page 36: ...ed for the application 4 NPT permanent instrument gages can be installed into the gage ports for calibration requirements WIRING TYPE AV2 POSITIONER Use the following procedure to wire the Type AV2 positioner 1 Connect the four to 20 mA position demand signal wires to terminals TB1 4 and TB1 5 of the terminal block Figs 3 2 and 3 15 For Type AV27 positioners unscrew the I P cover and make the four...

Page 37: ...anadian Electrical Code CSA c22 1 A grounding screw is provided inside the enclosure for grounding denoted by NOTES 1 The grounding screw located inside the enclosure is a safety ground and should not be used to ground the shielded pair 2 The positioner must be grounded to avoid ground loop conditions Figure 3 10 Direct Acting Top Loaded Single Acting Tubing Example HANDJACK T00890A O1 OUTPUT GAGE...

Page 38: ...2 PORT SIGNAL GAGE T00892A MOTION WITH INCREASING SIGNAL NOTES 1 RED CAM ROTATES CLOCKWISE WHEN VIEWED FROM THE FRONT 2 O2 PORT PLUGGED 3 STEM MOVES DOWN WITH SIGNAL FAILURE 4 STEM MOVES UP WITH SUPPLY AIR FAILURE G3 G1 MOTION WITH INCREASING SIGNAL HANDJACK O2 OUTPUT GAGE O2 PORT SIGNAL GAGE T00893A NOTES 1 BLACK CAM ROTATES COUNTERCLOCKWISE WHEN VIEWED FROM THE FRONT 2 O2 PORT PLUGGED 3 STEM MOV...

Page 39: ...4 VDC power supply in series with the required output load Table 1 5 to terminals TB1 1 and TB1 2 Figs 3 2 and 3 15 Refer to Appendix A for detailed information about position transmitters 2 If equipped with an optional potentiometric position transmitter Type AV1___1__ connect a power supply maximum 35 VDC or 30 VAC across TB1 1 and TB1 3 Use the signal across TB1 1 and TB1 2 or TB1 2 and TB1 3 f...

Page 40: ...NG THE REVERSE ACTING CAM LOCATED IN POSITIONER COVER AND REVERSING THE O1 AND O2 CONNECTIONS GAGE DESIGNATIONS G1 SIGNAL GAGE G2 OUTPUT GAGE O1 PORT G3 OUTPUT GAGE O2 PORT T00773A DIRECT ACTING BLACK CAM O1 O2 G3 G3 G2 G2 G1 G1 O1 O2 REVERSE ACTING RED CAM MOTION WITH INCREASING SIGNAL MOTION WITH INCREASING SIGNAL NOMEN CLATURE AV23 AV33 AV44 AV 1 AV 2 1 2 3 TB1 CONNECTIONS T00807A 4 5 24 ...

Page 41: ...a safety ground and should not be used to ground the shielded pair 2 The positioner must be grounded to avoid ground loop conditions RADIO FREQUENCY INTERFERENCE Most electronic equipment is influenced by radio frequency inter ference RFI Caution should be exercised with regard to the use of portable communications equipment in the area ABB recommends posting appropriate signs in the plant Refer t...

Page 42: ......

Page 43: ...ormally consists of adjusting the connection between the positioner and actuator so that the mechanical zero on the posi tioning cam corresponds to the mechanical zero of the actuator The calibration procedure detailed here involves fine adjustments to the zero and span such that the input signal will cause the desired travel Calibration consists of applying an input signal pressure to the positio...

Page 44: ...1 with the inch Allen wrench 3 Turn the zero adjustment nut clockwise moves the actuator toward minimum span until the zero radial line on the cam inter sects with the center of the cam roller Fig 4 2 NOTE This adjustment may be biased i e turning the zero adjustment nut slightly clockwise to make sure a valve or damper is firmly seated at the minimum input signal 4 Tighten the zero adjustment set...

Page 45: ... to its fully opened position Type AV2 Apply 20 mA The actuator should move to its fully opened position 2 To adjust the span loosen the span adjustment screw Fig 4 1 using a inch Allen wrench 3 Slide the span adjustment assembly Fig 4 1 in the appropri ate direction until the actuator moves to align the 100 radial line with the center of the cam roller toward pilot valve increases span of actuato...

Page 46: ... input signal For example the span may be adjusted to allow full actuator travel to occur with a signal change as small as 50 percent of its full span e g split ranging Fig 4 4 At the other extreme the span adjustment can be set to produce as little as 50 percent of the travel capability of the actuator over the full input signal pressure span e g short stroking This flexibility in span adjustment...

Page 47: ...itioner are two different gain hinge springs If actuator oscillation occurs the overall positioner gain may be too high Positioner gain is related to the thickness of the gain hinge spring Gain decreases as the thickness of the gain hinge spring increases Refer to Table 4 1 for hinge information For information on changing the gain hinge spring refer to Gain Hinge Spring in Section 8 Figure 4 4 Sp...

Page 48: ...ifices are too small causing the actuator to respond too slowly they may be drilled out to obtain desired speed control Blank orifices are also available Refer to Table 1 9 for orifice part numbers PILOT VALVE STROKE ADJUSTMENT If it is necessary to reduce the speed of operation a pilot valve stroke adjustment can reduce the speed and does not require additional hardware This adjustment limits the...

Page 49: ...pring Fig 4 6 This adjustment controls the amount of air going to port 02 NOTE To adjust the pilot valve stroke to the factory setting refer to PILOT VALVE STROKE ADJUSTMENT in Section 8 3 Test for satisfactory stroke time and adjust as required Figure 4 5 Pilot Valve Adjustment Figure 4 6 Speed Adjustment Screws STEM IS FLUSH WITH BODY 0 030 0 030 STEM POSITION AT BALANCE CONDITION STEM POSITION ...

Page 50: ...o monitor the signal pressure during calibration 2 Turn on the supply air to the positioner 3 Provide a four mA signal to the I P converter and observe the output pressure If the pressure equals 20 7 kPa 3 0 psig go to Step 5 If the pressure does not equal 20 7 kPa 3 0 psig go to Step 4 4 Adjust the zero screw 0 on the bottom of the I P con verter Fig 4 7 until the output pressure equals 20 7 kPa ...

Page 51: ...CALIBRATION TROUBLESHOOTING CALIBRATION ADJUSTMENTS 4 9 Figure 4 7 I P Adjustment T00779A ...

Page 52: ......

Page 53: ...e aware that if the actuator is not secured before transferring the valve handle of the manifold the actuator will move Transfer from Automatic to Manual Operation 1 Manually lock the actuator or final control element 2 If equipped with a manifold and equalizing valve push in the valve handle and turn it to the MAN position 3 If not equipped with a manifold and equalizing valve turn off the supply...

Page 54: ...ss the valve handle and turn it to the AUTO position The actuator will oppose the manual operator if the drive posi tion and input signal do not correspond b Manually operate the actuator until the load on the man ual operator decreases If the output pressure gages are installed on the positioner the gage readings should equalize NOTE If in Step 3 it is desired that the drive stay in its initial p...

Page 55: ...ce Refer to Pilot Valve Assembly in Section 8 Gain too high Change gain hinge spring to greater thickness Refer to Gain Hinge Spring in Section 8 Actuator at one end of stroke and does not respond to input change Air lines in wrong ports Check air line connections Figs 3 10 3 11 3 12 3 13 and 3 14 Incorrect cam installed for applica tion Determine application reverse or direct acting and check for...

Page 56: ...bration or not functioning Calibrate I P converter Refer to TROUBLESHOOTING CALI BRATION ADJUSTMENTS in Section 4 If unable to cali brate replace I P converter Refer to I P Converter in Section 8 Full range cannot be obtained with mechanical zero and span adjustment Signal diaphragm leaking Replace diaphragm Refer to Diaphragm Assembly in Section 8 I P converter out of calibration or not functioni...

Page 57: ...rval The maintenance intervals are recommendations and may vary depending on the location environment and the air qual ity of the positioner As a minimum these recommended mainte nance tasks should be performed during an extended process shutdown Some tasks in Table 7 1 are self explanatory Instructions for tasks that require further explanation are covered under PREVENTIVE MAINTENANCE PROCEDURES ...

Page 58: ... and lubricate the three O rings Fig 7 2 using the lubricant supplied in the kit Dow Corning No 4 5 Clean and place the cover over the filters and replace the cover screw Torque the cover screw to two Nm 18 in lbs Check all air connections for leakage while positioner is under pressure Use a soapsuds solution 12 Check the signal diaphragm for leaks use a soapsuds solution Clean pilot valve and ste...

Page 59: ...ioner back to automatic operation Section 5 Figure 7 1 Positioner with Manifold Figure 7 2 Manifold with Filter Cover Removed T00738A COVER SCREW FILTER COVER VALVE HANDLE ALLEN SCREWS S AUTO O2 O2 O1 O1 I I MAN TP00780A S AUTO O2 O2 O1 O1 I I MAN O RINGS ...

Page 60: ......

Page 61: ... on the valve handle and move it to the MAN position Fig 8 1 3 Remove the four Allen screws that secure the manifold Fig 8 1 4 Lift the manifold off the positioner 5 Before replacing the manifold make sure there are no deposits on the bosses of the positioner or on the back of the manifold If there are remove the deposits 6 Replace the O rings or clean them if they are in good condition Fig 8 2 7 ...

Page 62: ...7 Gain Hinge Spring NOTES 1 Refer to Table 4 1 for gain hinge spring part numbers 2 Item numbers in this procedure reference Figure 9 3 or 9 4 Tools Required Flat tip screwdriver inch Allen wrench 1 Transfer the positioner from automatic to manual operation Section 5 2 Remove the positioner cover by removing the two cover screws 3 Remove the plug button Item 29 from the positioner housing This ope...

Page 63: ...in hinge spring hangs up remove and rotate the hinge 90 Check for proper seating 7 Insert and torque the screws to 2 6 0 2 Nm 23 2 in lbs while holding the beam assembly steady Item 6 Insert the two screws that secure the hinge to the housing first 8 Transfer the positioner back to automatic operation Section 5 9 Perform the procedure outlined in PILOT VALVE STROKE ADJUSTMENT Pilot Valve Assembly ...

Page 64: ...place 7 Secure the valve body by replacing and tightening the pilot valve screws to 2 6 0 2 Nm 23 2 in lbs 8 Make certain the valve stem is clean Install the valve stem 9 Install the valve clip 10 Transfer the positioner back to automatic operation Section 5 11 Perform the procedure outlined in PILOT VALVE STROKE ADJUSTMENT I P Converter NOTES 1 Refer to Section 9 for I P converter part numbers 2 ...

Page 65: ...ioner cover by removing the two cover screws 3 Remove the indicator screw Item 51 and indicator Item 19 4 Hold and stop the cam shaft from rotating if it is not secured by linkage or coupling Using the adjustable wrench remove the cam nut Item 30 and washer Item 55 5 Lift the cam from the cam shaft 6 To replace the cam determine which cam mounting hole A B or C is appropriate for the application a...

Page 66: ...iaphragm support Item 23 5 Carefully remove the large diaphragm Item 73 from assembly 6 Remove the diaphragm spacer Item 22 7 Remove the diaphragm ring Item 24 8 Carefully remove the small diaphragm DIAPHRAGM ASSEMBLY REPLACEMENT 1 Place the small diaphragm Item 20 in the diaphragm housing with the concave side facing up Check for correct alignment of the tabs relative to the diaphragm housing 2 P...

Page 67: ...and check for leaks around the diaphragm assembly using soapsuds solution 11 Perform the procedure outlined in PILOT VALVE STROKE ADJUSTMENT PILOT VALVE STROKE ADJUSTMENT The purpose of this adjustment is to keep the valve stem in the proper operating range This procedure should be used in con junction with the following procedures Gain Hinge Spring Pilot Valve Assembly Diaphragm Assembly NOTE For...

Page 68: ...til the measurement matches the value shown in Figure 8 3 Figure 8 3 also shows the way the mea surement is taken 5 Apply the minimum input span to the positioner AV11 20 7 kPa 3 0 psig AV12 20 7 kPa 3 0 psig AV23 4 mA 6 Use the long inch Allen wrench to adjust the lower stroke adjustment screw Fig 8 4 Adjust the screw until the measurement matches the value shown in Figure 8 3 Figure 8 3 Pilot Va...

Page 69: ...AIR AND REPLACEMENT PILOT VALVE STROKE ADJUSTMENT 8 9 Figure 8 4 Stroke Adjustment Screws LOWER ADJUSTMENT SCREW HINGE SPRING SIGNAL DIAPHRAGM TOP ADJUSTMENT SCREW RANGE SPRING ALLEN WRENCH ACCESS T00778A ...

Page 70: ...REPAIR AND REPLACEMENT PILOT VALVE STROKE ADJUSTMENT 8 10 ...

Page 71: ...ive supply the kit numbers or if the items are not of a kit supply the part numbers NOTE This is not a complete list of available parts refer also to in this section and Table 1 7 in Section 1 NOTE 1 Kit contains SEM screw NBMMA13006A as of Novem ber 2009 Serial Number 3K620000029936 Table 9 1 Shutoff Valve Kit No 258270_1 positioners equipped with optional manifold Type AV___1 2 ___ Description P...

Page 72: ...3_2 1 Diaphragm support AV16 Table 9 4 Filter Replacement Kit No 258487_1 positioners equipped with optional manifold Type AV___1 2___ Part No Qty Description 19984_1 1 O ring lubricant 5311428_1 3 O rings 5400057_1 3 Filters Table 9 5 Pilot Valve Assembly Kit No 258488_1 for Types AV11 AV12 and AV2 Item Part No Qty Description 3 5400259_1 1 Valve stem 4 5400260_1 1 Valve body 5 5400261_1 1 Valve ...

Page 73: ...79_010 3 O rings 19984_1 1 O ring lubricant Table 9 9 Cam select appropriate cam type Part No Qty Description 5400281_1 1 Forward acting full rise cam 90 rotation 5400281_2 1 Reverse acting full rise cam 90 rotation 5400289_1 1 Forward acting half rise cam 45 rotation 5400289_2 1 Reverse acting half rise cam 45 rotation Table 9 10 AV2 I P Assembly Kit No 258651_1 Part No Qty Application Descriptio...

Page 74: ...0257_1 1 Cover insert 2 5400255_1 1 Window 5 5400257_2 1 Cover insert 3 5400256_1 1 Gasket 6 1964033 _1 1 Styleplate Table 9 15 Cover Assembly Kit No 258545_1 for Types AV15 and AV16 replaces part no 5400258 _1 Item Part No Qty Description Item Part No Qty Description 1 5400254_1 1 Cover 5 5400257_2 1 Cover insert 2 5400255_1 1 Window 6 1964033_1 1 Styleplate 4 5400257_1 1 Cover insert 10 R9025 00...

Page 75: ...g bracket 12 197120_5 Nut elastic stop 2 req 2 0 250 20 x 0 750 Screw socket head 3 req 13 5311690_1 Adjustable stud 2 69 in 3 0 250 Lock washer reg spring 3 req 14 5311690_2 Adjustable stud 3 43 in 5 0 312 18 x 0 625 Cap screw hex socket head 2 req 21 0 375 Lock washer med spring 3 req 6 0 312 Lock washer reg spring 2 req 22 0 375 24 Nut hex jam 7 R6440 005 Type 347 stainless steel wire 0 300 dia...

Page 76: ...ocating motion 2 When fastening Item 10 to the drive arm at the first hole nearest the drive shaft use Items 8 and 9 and omit one of Item 11 Table 9 22 Positioner Mounting Kit Number 5327321 _141 for use on Fisher Actuators Valve Stem Diameter 0 375 to 0 750 in Fig 9 1 Item Part Number Description Item Part Number Description 1 5400266_1 Positioner mounting bracket 112 0 190 32 x 0 875 Screw pan h...

Page 77: ... 320 74 04 2 915 57 15 2 250 23 62 0 930 57 15 2 250 93 90 3 697 Table 9 23 Rotary Actuator Retrofit Mounting Kits Kit Number Drive Nomenclature Retrofit Mounting Kit 5400309_1 UP1 UP2 Type AP positioner to Type AV positioner 258493_1 UP3 UP4 258494_1 UP5 UP6 258527_1 AC0404 258528_1 AC0608 258529_1 AC0816 258530_2 AC1016 258527_1 AC0404 ABB part number pilot valve positioner to Type AV positioner...

Page 78: ...ption 1 5327226_1 3 way valve 2 5326946_1 Air line connection assy 3 195159_3 Elbow connector 4 195727_2 Brass nipple 5 195171_3 Wheatherhead tee 6 1962833_1 Designation plate 7 NBZAC16006 Screw pan head 8 NTJAC09030 Lock washer 9 NLMAC16000 Nut hex 10 1951041_1 Sch pipe plug Figure 9 2 Bypass Valve Assembly 6 8 7 3 4 10 1 9 2 5 D5326945 T00786A ...

Page 79: ...hragm spacer 68 R9025 0046 Tubing 6 4 cm 2 5 in 23 Refer to Table 9 26 Diaphragm support 69 1951651_1 Plug 24 5400294_1 Diaphragm ring 71 193197_1 Span adjustment bearing 25 Refer to Table 9 26 Diaphragm cover 72 114B094U01 Plug button 26 5400296_1 Exhaust mesh 73 Refer to Table 9 26 Large diaphragm 27 193243_1 Large position transmitter gear1 74 NDPAC15004 Screw 28 1951652_1 Barb fitting 2 req 75...

Page 80: ... 5400295_1 1945803_1 1951779_10 5400288_4 1951755_3 Omit 1951799_206 Omit 2 Omit AV15____N 5400258_3 5400260_1 5400288_5 5400293_1 5400295_1 1943573_1 1951779_10 5400288_4 1951755_3 Omit 1951799_206 Omit 2 1 AV15____P 5400258_3 5400260_2 5400288_5 5400293_1 5400295_1 1945803_1 1951779_10 5400288_4 1951755_3 Omit 1951799_206 Omit 2 Omit AV16 ____0 5400258_3 5400260_1 5400288_5 5400293_2 5400295_2 1...

Page 81: ...7 67 17 FRONT VIEW 37 41 40 2 1 1 2 3 4 5 VIEW WITH COVER REMOVED INSIDE OF COVER 43 81 10 26 58 56 49 59 12 8 3 52 4 45 16 13 6 7 42 11 82 94 64 5 81 61 9 86 58 58 15 44 70 75 39 38 82 43 81 2 36 13 74 96 87 88 51 19 55 32 30 13 31 62 18 68 28 7 20 24 22 73 23 54 53 25 47 28 14 35 69 2 44 44 43 72 50 9 46 93 48 1 33 71 31 32 63 34 ...

Page 82: ...ve body 57 Form MP432 889 Label indicator 5 5400261_1 Valve clip 58 197893_1 Thread forming screw 8 req 6 5400263_1 Beam assembly 59 6639559_1 Termination assembly 7 5400264_1 Hinge 61 197893_1 Label CSA FM 8 258544_1 Cam follower arm assembly 62 1963318_ _ Nameplate universal 9 5400271_1 Spring arm 63 Refer to Table 9 31 Drive arm1 10 5400272_1 Pivot 64 5311428_207 Manifold O ring1 11 5400273_1 E...

Page 83: ... NKJHA13004 Socket head cup pt set screw1 47 197865_1 Stroke adjustment screw 105 NKJHA16004 Socket head cup pt set screw1 48 NKJHA16004 Zero adjustment set screw 106 1951041_4 Socket head pipe plug1 49 NBAHA16020 Span adjustment screw 107 NKJHA23006 Socket head cup pt set screw1 50 1951041_1 Socket head pipe plug 108 1951631_206 O ring 51 NIDHA13005 Indicator screw 109 258567_1 NEMA 4X kit1 52 NI...

Page 84: ...0281_1 2 5400287_3 114B095U01 Omit 2 Omit Omit Omit AV232__40 5400260_1 5400281_1 2 5400287_4 114B095U01 Omit 2 Omit Omit Omit AV232__4N 5400260_1 5400281_1 2 5400287_4 1943573_1 Omit 2 Omit 2 1 AV232__4P 5400260_2 5400281_1 2 5400287_4 114B095U01 Omit 2 Omit Omit Omit AV232__50 5400260_1 5400281_1 2 5400287_5 114B095U01 Omit 2 Omit Omit Omit AV232__5N 5400260_1 5400281_1 2 5400287_5 1943573_1 Omi...

Page 85: ...4 114B095U01 Omit 2 Omit Omit Omit AV272_04N 5400260_1 5400281_1 2 5400287_4 1943573_1 Omit 2 Omit 2 1 AV272_04P 5400260_2 5400281_1 2 5400287_4 114B095U01 Omit 2 Omit Omit Omit AV272_050 5400260_1 5400281_1 2 5400287_5 114B095U01 Omit 2 Omit Omit Omit AV272_05N 5400260_1 5400281_1 2 5400287_5 1943573_1 Omit 2 Omit 2 1 AV272_05P 5400260_2 5400281_1 2 5400287_5 114B095U01 Omit 2 Omit Omit Omit NOTE...

Page 86: ...T00784A 58 81 81 87 88 68 58 80 51 19 30 55 13 32 62 14 35 50 44 2 1 38 31 43 74 61 46 18 7 20 24 22 73 23 54 53 25 47 63 32 34 108 39 44 15 48 85 77 70 93 94 76 58 SIDE VIEW O1 O2 O2 O1 I I S 65 65 65 65 66 66 67 67 17 FRONT VIEW 37 10 71 41 40 2 1 33 INSIDE OF COVER 2 36 110 82 13 90 101 ...

Page 87: ...PARTS 9 17 Figure 9 5 Type AV2 Positioner Page 2 of 2 Table 9 34 Conversion Kits Part No Qty Application Description 258651_1 1 AV23 I P Conversion Kit1 NOTE 1 Replaces older I Ps that required an internal 22 psi pressure pre regulator ...

Page 88: ......

Page 89: ...ositioner cam shaft The position of the potentiometer shaft indicates the position of the actuator The relationship between the potentiometer and the cam shaft results in one degree of rotation of the cam shaft corresponding to approximately 9 9 ohms of resistive change at the potentiometer wiper Three leads from the potentiometer are for customer use and are available at terminals TB1 1 TB1 2 and...

Page 90: ...omenclature and terminal connections of Figure A 1 are AV23 The positive and negative connections at position TB1 4 and TB1 5 refer to the four to 20 milliamp signal to the I P con verter AV33 Not applicable AV44 Not applicable AV____1__ Depicts the connections for the potentiometric position trans mitter option AV____2__ The positive and negative connections at position TB1 1 and TB1 2 refer to t...

Page 91: ...f rotation For every degree of rotation the resistive change is 9 9Ω nominally 72 x 9 9 Ω 712 8 Ω The change of resistance for this rotation is 712 8 Ω and appears between TB1 1 and TB1 2 3 To guard against wrap around the minimum resistance at the potentiometer wiper at zero percent cam rotation is set to 200 Ω Therefore the resistance between TB1 1 and TB1 2 should vary between 200 and 912 8 712...

Page 92: ... flag nut and washer Fig A 3 and Table A 1 b Loosen the set screw on the hub of the small gear using a in Allen wrench Fig A 3 and Table A 1 c Use a screwdriver to adjust the shaft on the potentiometer until the ohmmeter reads 200 20 Ω While adjusting the resistance hold the gears and cam shaft stationary so rotation does not occur Only the potentiometer shaft should move while adjusting the resis...

Page 93: ...xploded View Table A 1 Potentiometric Position Transmitter Kit 258670_1 Item No Part No Qty Description 21 6639540_2 1 Potentiometer assembly 27 193243_1 1 Large position transmitter gear 31 19734_45 1 Washer 60 5400317_1 1 Gear adapter 92 NDPAC13012 2 Threaded forming screw 95 5400268_1 1 Potentiometer mounting bracket 96 193242_1 1 Small position transmitter gear NOTES 1 SOME HARDWARE ITEMS HAVE...

Page 94: ...tentiometers and field connec tion terminals for the position transmitter Figs A 1 and A 4 1 Remove the FOR REV jumpers and place the CAL OPER jumpers in the calibrate CAL position Fig A 4 2 Move the actuator to the 50 output position 3 Insert ohmmeter leads into test jacks TP1 and TP2 If the resistance value is between 940 and 1060 Ω remove the ohm meter leads and proceed to Step 4 Otherwise cont...

Page 95: ...er gear 31 19734_45 1 Washer 58 NDPAC13005 2 Threaded forming screw 60 5400317_1 1 Gear adapter 91 6639479_1 1 4 to 20 mA position transmitter assem bly 92 NDPAC13012 2 Threaded forming screw 95 5400268_1 1 Potentiometer mounting bracket 96 193242_1 1 Small position transmitter gear 21 91 58 95 96 31 60 27 92 POTENTIOMETER 2000 Ω SET SCREW CAM FLAG MOUNTING BRACKET SMALL GEAR LARGE GEAR NOTES 1 SO...

Page 96: ... TB1 2 Install the cam screw flag nut and washer Fig A 5 and Table A 2 4 Place the CAL OPER jumpers into the operate OPER posi tion Fig A 4 If a direct acting cam is being used place the FOR REV jumpers in the FOR position For a reverse acting cam place these jumpers in the REV position Fig A 4 5 Connect a 24 VDC external power supply across TB1 1 and TB1 2 6 Move the actuator to the 0 position In...

Page 97: ...o 15 0 psig Type AV1 2 20 7 to 186 2 kPa 3 0 to 27 0 psig Type AV1 3 4 to 20 mA standard intrinsically safe Type AV2 5 20 7 to 103 4 kPa 3 0 to 15 0 psig high temperature applications Type AV1 1 6 20 7 to 186 2 kPa 3 0 to 27 0 psig high temperature applications Type AV1 1 7 4 to 20 mA with explosionproof I P converter NEMA 7 Type AV2 2 Stroke Rotary Motion cam selection 1 12 7 to 50 8 mm 0 5 to 20...

Page 98: ...pplication 3 With the actuator in the closed position adjust the connecting linkage so that the zero radial line on the cam intersects the center of the cam roller Fig B 4 4 Lock all linkage components in place Drive Shaft 0 Standard with feedback arm for linear motion 1 0 500 in square end 2 0 342 in square end for older DeZurik actuators 3 0 250 in across flats UP1 and UP2 after August 1995 4 0 ...

Page 99: ...PLATE FRONT VIEW SIDE VIEW T00802A MOUNTING BRACKET ADJUSTABLE CONNECTING LINK ADJUSTABLE STUD PAN HEAD MACHINE SCREW NOTE DRIVE ARM SHOULD BE PERPENDICULAR WITH THE ACTUATOR AT MIDSTROKE G2 G1 Figure B 2 Mounting Using Direct Coupling Typical AV 1 POSITIONER T00803A ROTARY ACTUATOR ACTUATOR SHAFT AV OUTPUT SH AFT COUPLING SET SC REW S ...

Page 100: ...AM STROKE 90 OR FULL CAM 0 193 200 4 9 5 1 7X T00804A_flats TYPE AV 0 DIMENSIONS INCHES MILLIMETERS 0 65 16 5 0 33 8 4 0 35 8 9 4 00 101 6 2 00 50 8 3 00 76 2 1 50 38 1 3 50 88 9 1 75 44 5 2 50 63 5 1 25 31 8 1 50 38 1 0 75 19 1 2 00 50 8 1 00 25 4 1 00 25 4 0 50 12 7 TYP TYP 0 71 18 0 T00771A CAM FOLLOWER ARM CAM ROLLER CAM ...

Page 101: ...r paste pipe sealant to seal the connection Max imum torque for NPT fittings is 13 6 Nm 10 0 ft lbs 3 Connect the output ports 01 and 02 as required to provide the desired direction of rotation Figures B 6 B 7 B 8 and B 9 show a single acting tubing example and Figure B 10 shows a double acting tubing example NOTE The piping arrangements shown in Figures B 6 B 7 B 8 B 9 and B 10 are general exampl...

Page 102: ... MOTION WITH INCREASING SIGNAL NOTES 1 BLACK CAM ROTATES COUNTERCLOCKWISE WHEN VIEWED FROM THE FRONT 2 O2 PORT PLUGGED 3 STEM MOVES UP WITH SIGNAL OR SUPPLY AIR FAILURE G2 G1 G3 G1 HANDJACK ALTERNATE PIPING FOR DIAPHRAGM ACTUATOR WITH HANDJACK O2 OUTPUT GAGE O2 PORT SIGNAL GAGE T00892A MOTION WITH INCREASING SIGNAL NOTES 1 RED CAM ROTATES CLOCKWISE WHEN VIEWED FROM THE FRONT 2 O2 PORT PLUGGED 3 ST...

Page 103: ...UTPUT GAGE O2 PORT SIGNAL GAGE T00893A NOTES 1 BLACK CAM ROTATES COUNTERCLOCKWISE WHEN VIEWED FROM THE FRONT 2 O2 PORT PLUGGED 3 STEM MOVES UP WITH SIGNAL FAILURE 4 STEM MOVES DOWN WITH SUPPLY AIR FAILURE G2 G1 HANDJACK O1 OUTPUT GAGE O1 PORT SIGNAL GAGE T00891A MOTION WITH INCREASING SIGNAL NOTES 1 RED CAM ROTATES CLOCKWISE WHEN VIEWED FROM THE FRONT 2 O2 PORT PLUGGED 3 STEM MOVES DOWN WITH SIGNA...

Page 104: ...he enclosure so that bare wires are not exposed 2 If equipped with an optional 4 to 20 mA position transmitter AV2___2__ connect a 24 VDC power supply in series with the required output load Table 1 5 to terminals TB1 1 and TB1 2 Figure B 10 Double Acting Tubing Example NOTE IN ANY INSTALLATION DIRECTION OF PISTON TRAVEL CAN BE REVERSED BY USING THE REVERSE ACTING CAM LOCATED IN POSITIONER COVER A...

Page 105: ...mation about position transmitters NOTE Route the wiring inside the positioner so it does not become entangled with moving parts A cable clamp Figure B 12 is pro vided inside the positioner so entanglement can be avoided Figure B 11 Wiring Connections NOMEN CLATURE AV23 AV33 AV44 AV 1 AV 2 1 2 3 TB1 CONNECTIONS T00807A 4 5 24 Figure B 12 Calibration Adjustments OPTIONAL MANIFOLD PILOT VALVE CONDUI...

Page 106: ...__2__ connect a 24 VDC power supply in series with the required output load Table 1 5 to terminals TB1 1 and TB1 2 Fig B 11 Refer to Appendix A for detailed information about posi tion transmitters 2 If equipped with optional potentiometric position transmitter Type AV1___2__ connect a power supply maximum 35 VDC or 30 VAC across TB1 1 and TB1 3 Use the signal across TB1 1 and TB1 2 or TB1 2 and T...

Page 107: ...n the cam intersects with the center of the cam roller Fig B 4 4 Tighten the zero adjustment setscrew 4 Tighten the zero adjustment setscrew Span 1 Apply the following input signal pressures depending on the nomenclature type Types AV11 and AV15 103 4 kPa 15 0 psig Actuator should move to its full open position Types AV12 and AV16 186 2 kPa 27 0 psig Actuator should move to its full open position ...

Page 108: ......

Page 109: ...medium versus control signal character istic An example is a desired flow rate of air water or steam through a valve for each control signal pressure applied to the positioner The control characteristics for which the cams are shaped are listed in Table 3 1 and are shown in Figures C 1 C 2 and C 3 The figures show a family of curves for each cam whose boundaries are established by a span adjustmen...

Page 110: ...0 50 50 10 90 60 40 70 30 80 20 90 10 100 0 SOLID LINE INDICATES FORWARD TRAVEL DIRECT ACTING DASHED LINE INDICATES REVERSE TRAVEL REVERSE ACTING LIMITED SIGNAL LIMITED TRAVEL 100 40 10 20 30 90 50 60 70 80 0 SCALE OF SIGNAL RANGE SCALE TRAVEL T00793A 0 100 20 80 30 70 40 60 50 50 10 90 60 40 70 30 80 20 90 10 100 0 SOLID LINE INDICATES FORWARD TRAVEL DASHED LINE INDICATES REVERSE TRAVEL LIMITED S...

Page 111: ...the B linear cam in place determine and plot the actual controlled medium versus piston or valve position characteristic by manually adjusting valve position and measuring the controlled medium Fig C 4 Table C 1 Control Signal Pressure Conversions AV1 of Control Signal Control System Spans of Control Signal Control System Spans 20 7 to 103 4 kPa 3 0 to 15 0 psig 20 7 to 186 2 kPa 3 0 to 27 0 psig ...

Page 112: ...the drive linkage replot the controlled medium versus piston travel curves In all cases avoid overstroking the final control device Figure C 4 Regulated Device Characteristics Figure C 5 Desired Control 100 40 10 20 30 90 50 60 70 80 0 OF PISTON OR VALVE TRAVEL OF CONTROLLED MEDIUM T00795A 0 20 30 40 50 10 60 70 80 90 100 100 40 10 20 30 90 50 60 70 80 0 OF SIGNAL OF CONTROLLED MEDIUM T00794A 0 20...

Page 113: ...djust the positioner zero and span as outlined under Zero Adjustment and Span Adjustment in Section 4 to make the control signal pressure versus piston or valve charac teristic conform better to the curve plotted in Step 3 6 If the required characteristic cannot be obtained using this pro cedure or if more exact characteristics are required alter the shape of a standard A B or C cam or cut a new c...

Page 114: ...from Table C 1 for the positioner being used 2 Refer to Figure C 7 for the method of transferring data from the graph to the cam For each radial line on the cam represent ing a percent piston or valve travel find the value of signal on the graph that corresponds to that percent piston or valve travel Pro ceed along the radial line to the concentric arc that represents the signal pressure for the r...

Page 115: ... 2 8 8 18 4 12 0 13 6 15 2 16 8 4 0 10 4 1 2 3 9 5 6 7 8 0 0 2 3 4 5 1 6 7 8 9 10 CAM RADIAL LINES OF PISTON OR VALVE TRAVEL SIGNAL RANGE 4 20 mA CAM CONCENTRIC LINES 0 20 30 40 50 10 60 70 80 90 100 T00797A 100 50 0 EXAMPLE CONTROLLED MEDIUM REQUIRED AT 7 8 PSIG TO BE AT 60 OF PISTON TRAVEL ...

Page 116: ......

Page 117: ...tion through the use of the A B or C por tion of the cam respectively Other characteristics may be created by shaping the cam Appendix C The Type AV1 positioner functions as a position transmitter by interconnecting the I input signal with the 02 output port and tap ping into this interconnection for the output signal A plug is placed in the 01 port The pneumatic position transmitter kit provides ...

Page 118: ...cting link as the positioner application For a 90 degree rotation device it may be desired to couple the cam shaft directly to the actuator The zero position of the cam shaft can be adjusted in 45 degree increments by reposi tioning the cam on the shaft The direction of the transmitted signal can be reversed by placing the reverse acting cam located on the inside of the positioner cover on the cam...

Page 119: ... 6 Adjust the pivot position on the arm Item 63 Fig 9 3 or other external linkage until the cam follower is at 100 of cam rotation radial line marked 100 on the cam 7 Repeat Steps 3 through 6 until the cam follower is at 0 cam when the actuator is at 0 stroke and 100 cam when the actua tor is at 100 stroke 8 Turn on the air supply 9 Move the actuator to the 0 stroke position 10 If the output is no...

Page 120: ... Moving the span adjustment assembly toward the valve body provides a longer actuator stroke for a given signal change i e increases the range of travel for the cam follower arm Moving the span adjustment bearing away from the valve body causes the opposite to occur i e decreases the range of travel for the cam follower arm ...

Page 121: ...acing 8 5 Reverse acting 3 6 Roller alignment 3 8 B 4 Selection C 3 Shaping C 5 Square 1 2 Square root 1 2 Capacity 1 8 D Deadband 1 8 Description 1 1 Diaphragm assembly replacement 8 5 Direct acting 3 6 Direct coupling mounting 3 6 B 3 Double acting actuator tubing connections 3 14 B 8 Drive arm connections 3 4 B 4 Drive shaft variations 3 5 E Electrical connections 3 4 Enclosure classification 1...

Page 122: ...tandard 3 3 Direct coupling 3 6 B 3 Drive arm connections 3 4 B 4 Drive shaft variations 3 5 Linkage 3 5 B 3 N NEMA 4X 1 3 Nomenclature 1 6 B 1 O Orifice 4 6 P Performance series 1 2 Pilot valve High gain 1 2 Performance series 1 2 Replacing 8 4 Stroke adjustment 4 6 8 7 Pneumatic connections 1 8 Port locations 3 9 B 5 Position transmitter 4 to 20 mA A 1 Calibration A 6 Calibration D 3 Description...

Page 123: ...nput impedance 1 7 Input range 1 7 Linearity 1 8 Materials of construction 1 8 Pneumatic connections 1 8 Repeatability 1 8 Resolution 1 8 Standard stroke range 1 8 Supply pressure 1 8 Supply pressure effect 1 8 Temperature limits 1 9 Vibration effect 1 8 Weight 1 9 Speed 4 5 Speed adjustment Orifice 4 6 Pilot valve stroke 4 6 Split ranging 4 4 Graph 4 5 Stroke adjustment pilot valve 8 7 Stroke ran...

Page 124: ...Index 4 Index continued Zero suppression 4 4 Zero suppression 4 4 Graph 4 4 ...

Page 125: ......

Page 126: ... the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB Copyright 2011 ABB All rights reserved Created in USA July 2011 OI AV12_07 11 ABB Limited Process Automation Oldends Lane Stonehouse Gloucestershire GL 10 3TA UK Tel 44 0 1453 826 661 Fax 44 0 1453...

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ABB AV1, Operating Instructions Manual

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